ZESCO Kariba North Power Plant

ZESCO Kariba North Power Plant – Valve blasting and coating restoration

ZESCO Kariba North Power Plant – Valve Blasting & Coating Restoration

Industrial Surface Protection & Engineering Restoration for Critical Power Infrastructure

The Ivey School of Business project is a landmark in modern educational construction, merging cutting-edge design with sustainable practices. This state-of-the-art facility was crafted to support advanced learning, research, and collaboration while reflecting the institution’s global reputation for excellence. Our mission was to transform the vision of an innovative educational space into reality, setting a new benchmark in construction for academic institutions.

ZESCO Kariba North Power Plant’s Challenge

The ZESCO Kariba North Power Plant is one of the largest hydropower stations in Southern Africa, supplying vital energy to Zambia and surrounding regions. Over time, key hydraulic and mechanical components of the plant—especially the large control valves and penstock structures—developed surface corrosion and coating failure due to continuous exposure to water pressure, humidity, and environmental wear.

SIROCCOI (U) Ltd was contracted to execute specialized valve blasting, surface preparation, and industrial coating restoration to enhance performance, prevent corrosion, and extend the operating life of critical infrastructure.

The ZESCO Kariba North Power Plant is one of the largest hydropower stations in Southern Africa, supplying vital energy to Zambia and surrounding regions.

Scope of Work

The project required SIROCCOI’s team to perform precision work on elevated, large-diameter steel components with limited access and strict safety and quality requirements. The key activities included:

High-pressure grit blasting was used to strip old coatings, scale, and rust from large steel valve surfaces, including internal chambers, flanges, and pipe interfaces.
Achieved near-white metal finish suitable for high-performance protective coatings, ensuring optimal bonding and long-term durability.
Multi-layered systems including epoxy primers and polyurethane topcoats were applied using airless spraying systems to meet ZESCO’s operational and environmental specifications.
Specialized access methods were used for hard-to-reach surfaces, ensuring comprehensive restoration without plant-wide shutdowns.
Coating thickness, adhesion, and surface condition were tested using Elcometer 456, 266, and 106 tools to verify compliance with project specifications.

Challenges & Solutions

Challenge 1: Confined and Elevated Work Areas
Our rope-access trained technicians safely accessed vertical and enclosed valve sections, using certified equipment and adhering to confined space entry protocols.

Challenge 2: Time-Sensitive Delivery
Work was completed within a restricted outage window. SIROCCOI deployed a fully equipped mobile team and operated in continuous shifts to meet the deadline.

Challenge 3: Harsh Environmental Exposure
The coatings were selected and applied based on corrosion class and exposure to high humidity, temperature fluctuations, and fluid abrasion.

Results/(Project Outcomes)

restoration of critical valve components
corrosion resistance and extended lifespan
safety incidents reported
client satisfaction and compliance with QA/QC benchmarks

Project Preview

ZESCO (Zambia Electricity Supply Corporation)
Kariba North Power Plant, Zambia
Valve Blasting, Surface Preparation & Coating Restoration
SIROCCOI (U) Ltd

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Let’s Build & Restore with Confidence

SIROCCOI (U) Ltd is proud to be a trusted partner in regional infrastructure reliability. Whether it’s corrosion control, industrial coating, or mechanical system restoration, we bring performance, safety, and precision to every project.

Call Now: +256 770 805 147 / 706 719 459 / 755 897 879
Email: siroccoi.ultd@gmail.com
Office: Accacia Close Magwa, Plot No.5, P.O BOX 5181, Jinja, Uganda